65-0229 - 7800 SERIES Relay Modules - Greenheck

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7800 SERIES RELAY MODULES IGNITION SPARK RESPONSE TEST (ALL ULTRAVIOLET DETECTORS) Test to make certain that the ignition spark is not actuating the FLAME LED: 1. Close the pilot and main burner manual fuel shut-off valve(s). 2. Start the burner and use the Run/Test Switch (if available) to stop the sequence in the PILOT IGN period. Ignition spark should occur, but the flame signal should not be more than 0.5 Vdc. 3. If the flame signal is higher than 0.5 Vdc and the FLAME LED does come on, consult the equipment operating manual and resight the detector farther out from the spark, or away from possible reflection. It may be necessary to construct a barrier to block the ignition spark from the detector view. Continue adjustments until the flame signal due to ignition spark is less than 0.5 Vdc. NOTE: The Honeywell Q624A and Q652A,B Solid State Spark Generators prevent detection of ignition spark when properly applied with C7027, C7035, C7044 or C7061 Ultraviolet Flame Detectors. The Q624A and Q652B are only for use with gas pilots; the Q652A is only for oil applications. Response To Other Ultraviolet Sources Some sources of artificial light (such as incandescent or fluorescent bulbs, mercury sodium vapor lamps and daylight) produce small amounts of ultraviolet radiation. Under certain conditions, an ultraviolet detector responds to these sources as if it is sensing a flame. To check for proper detector operation, check the Flame Failure Response Time (FFRT) and conduct Safety Shutdown Tests under all operating conditions. Flame Signal With Hot Combustion Chamber (All Installations) 1. With all initial start-up tests and burner adjustments completed, operate the burner until the combustion chamber is at the maximum expected temperature. 2. Observe the equipment manufacturer warm-up instructions. 3. Recycle the burner under these hot conditions and measure the flame signal. Check the pilot alone, the main burner flame alone, and both together (unless monitoring only the pilot flame when using an intermittent pilot, or only the main burner flame when using DSI). Check the signal at both High and Low Firing Rate positions and while modulating, if applicable. 4. Check the FFRT of the flame amplifier and relay module. 5. Lower the setpoint of the operating controller and observe the time it takes for the burner flame to go out. This should be within the maximum FFRT. 6. If the flame signal is too low or unsteady, check the flame detector temperature. Relocate the detector if the temperature is too high. 7. If necessary, realign the sighting to obtain the proper signal and response time. 8. If the response time is still too slow, replace the Plug-in Flame Signal Amplifier. 65-0229—1 6 9. If the detector is relocated or resighted, or the amplifier is replaced, repeat all required Checkout tests. SAFETY SHUTDOWN TESTS (ALL INSTALLATIONS) Perform these tests at the end of Checkout, after all other tests are completed. If used, the external alarm should turn on. Press the RESET pushbutton on the relay module to restart the system. 1. Opening a Preignition Interlock during the STANDBY or PREPURGE period (only for RM7800, EC/RM7840, RM7838B, EC7810, EC7820, EC/RM7830, EC/ RM7850). a. *Preignition ILK* fault is displayed on the Keyboard Display Module. Fault code 10 or 33 is displayed to denote the fault. b. Safety shutdown occurs. 2. Opening a Lockout Interlock during PREPURGE, PILOT IGN, MAIN IGN or RUN period (only for RM7800, EC/RM7840, RM7838B, EC7810, EC7820, EC/RM7830, EC/RM7850). a. *Lockout ILK* fault is displayed on the Keyboard Display Module. Fault code 11 or 12 or 21 or 29 is displayed to denote the fault. b. Safety shutdown occurs. 3. Detection of flame 40 seconds after entry to STANDBY from RUN, fault code 9. Detection of flame from ten seconds up to 30 seconds into PREPURGE time. a. Simulate a flame to cause the flame signal voltage level to be at least 1.25 Vdc for 40 seconds after entry to STANDBY from RUN and also simulate a flame signal for 10 seconds to 30 seconds for PREPURGE. b. *Flame Detected* fault is displayed on the Keyboard Display Module. Fault code 9 or 15 or 18 is displayed to denote the fault. c. Safety shutdown occurs. 4. Failure to ignite pilot. a. Close pilot and main fuel manual shutoff valve(s). b. Cycle burner on. c. Automatic pilot valve(s) should be energized but the pilot cannot ignite. d. *Pilot Flame Fail* fault is displayed on the Keyboard Display Module. Fault code 28 is displayed four or ten seconds, depending on the jumper configuration selection for Pilot Flame Establishing Period (PFEP) after the pilot valve(s) is energized to denote the fault. e. Safety shutdown occurs. 5. Failure to ignite main (only interrupted pilot application). a. Open the manual pilot valve(s); leave the main fuel manual shutoff valve(s) closed. b. Depress the RESET button. c. Start the system. d. The pilot should ignite and the flame signal should be at least 1.25 Vdc but the main burner cannot light. e. The flame signal should drop below 1.25 Vdc within the FFRT of the amplifier and the relay module after the interrupted pilot goes out. f. *Main Flame Ign.* fault is displayed on the Keyboard Display Module. Fault code 19 is displayed to denote the fault. g. Safety shutdown occurs.
6. Loss of flame during RUN. a. Open the main fuel manual shutoff valve(s) and open manual pilot shutoff valve(s). b. Depress the RESET button. c. Start the system. Start-up should be normal and the main burner should light normally. d. After the sequence is in the normal RUN period for at least ten seconds with the main burner firing, close the manual main fuel shutoff valve(s) to extinguish the main burner flame. (On intermittent pilot applications, also, close the pilot manual shutoff valve.) e. The flame signal should drop below 1.25 Vdc within the FFRT of the amplifier and the relay module after the main flame and/or pilot goes out. f. *Main Flame Fail* fault is displayed on the Keyboard Display Module. Fault code 17 is displayed to denote the fault. g. Safety shutdown occurs. (EC/RM7890, EC/ RM7895, RM7896 relay modules will recycle if jumper JR2 is intact, then lock out on failure to light the pilot.) 7. Opening a Preignition Interlock after the first five seconds of POSTPURGE. a. Open the main fuel manual shutoff valve(s) and open manual pilot shutoff valve(s). b. Depress the RESET button. c. *Preignition ILK* fault is displayed on the Keyboard Display Module. Fault code 33 is displayed to denote the fault. d. Safety shutdown occurs. IMPORTANT 1. If the relay module fails to shut down on any of these tests, take corrective action; refer to Troubleshooting and the relay module diagnostics and return to the beginning of all Checkout tests. 2. When all Checkout tests are completed, reset all switches to the original status. TROUBLESHOOTING System Diagnostics Troubleshooting control system equipment failures is easier with the relay module self-diagnostics and first-out annunciation. In addition to an isolated spst alarm relay (audible annunciation), the relay module provides visual annunciation by displaying a fault code and fault or hold message at the S7800 Keyboard Display Module (standard on RM7800 and RM7838A,B devices; optional on all others). The relay module provides 127 diagnostic messages for troubleshooting the system (see Table 3). Self-diagnostics of the relay module enables it to detect and annunciate both external and internal system problems. Fault messages, such as interlock failures, flame failures and false flame signals are displayed at the KDM, and annunciated at the 7800 SERIES Relay Module by the ALARM LED. 7800 SERIES RELAY MODULES The KDM displays a sequence status message indicating: STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE. The selectable messages also provide visual indication of current status and historical status of the equipment such as: Flame Signal, Total Cycles, Total Hours, Fault History, Diagnostic Information and Expanded Annunciator terminal status (if used). With this information, most problems can be diagnosed without extensive trial and error testing. Table 2 provides the sequence and status hold messages. Table 3 is a summary of all relay module fault messages, fault codes, and troubleshooting suggestions. In addition, Diagnostic Information and History Data are available to assist in troubleshooting the relay module. The relay module provides diagnostic information to aid the service mechanic in obtaining information when troubleshooting the system. Information available in the Diagnostic Information includes Device Type, Device Suffix, Software Revision, Manufacturing Code, Flame Amplifier Type, Flame Failure Response Time, Selectable Jumper Configuration Status, Run/Test Switch Status and Terminal Status. Diagnostic Information Index The relay module monitors input/output terminals and can display the status of the terminal at the KDM (see Table 2) (example: Pilot Valve T8 1). See the applicable relay module installation instructions for a complete terminal description and number. The display shows the actual status of the terminal. If voltage is detected at the terminal, 1 is displayed, but if no voltage is detected at the terminal, 0 is displayed. Historical Information Index The relay module has nonvolatile memory that allows the Relay Module to retain historical information for the six most recent lockouts. Each of the six lockout files retains the cycle when the fault occurred, the hour of operation when the fault occurred, a fault code, a fault message and burner status when the fault occurred. IMPORTANT Some older relay modules can not operate without a KDM, extension cable assembly with KDM or a Data ControlBus Module installed. SERVICE NOTES: 1. If the KDM is scrambled, remove and reinstall the KDM, and reset the 7800 Relay Module. 2. Reset the 7800 Series Relay Module by pressing the RESET pushbutton on the 7800 Series Relay Module, or pressing a remote reset pushbutton wired through the KDM, Data ControlBus Module or Remote Reset Module. A power-up reset causes an electrical reset of the relay module but does not reset a lockout condition. 3. Use the access slots on the sides of the Q7800A,B to check terminal voltage. 4. Maximum ambient operating temperature of a C7012E,F; Series 1 through 6, is reduced to 125°F because of the duty cycle operation of the relay module. 7 65-0229—1
Page 1 and 2: ® U.S. Registered Trademark Copyri
Page 3 and 4: . On the subbase, jumper L1 to the
Page 5: 12. Close the master switch to recy
Page 9 and 10: Table 2. Keyboard Display Module Se
Page 11 and 12: Table 3. Hold and Fault Message Sum
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65-0229 - 7800 SERIES Relay Modules - Greenheck

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